Process for and processor of natural gas and activated carbon together with blower

ABSTRACT

A method of and device for processing carbonacious material into gas and activated carbon together with blower.

CROSS REFERENCE OF RELATED APPLICATIONS

The present application is a continuation of U.S. application Ser. No.12/590,391 (the '391 application), filed Nov. 5, 2009 entitled PROCESSFOR AND PROCESSOR OF NATURAL GAS AND ACTIVATED CARBON TOGETHER WITHBLOWER, which is a continuation of U.S. application Ser. No. 12/291,188(the '188 application), filed Nov. 6, 2008 entitled FLOW RATE OF GAS INFLUIDIZED BED DURING CONVERSION OF CARBON BASED MATERIAL TO NATURAL GASAND ACTIVATED CARBON and claims priority therefrom. The '188 applicationclaims benefit of U.S. Provisional Patent Application 61/004,082, filedNov. 23, 2007 entitled CLOSED LOOP FLUIDIZED BED FLASH GASIFICATIONSYSTEM and U.S. Provisional Patent Application 61/137,213, filed Jul.28, 2008 entitled LIQUIFACTION PROCESS FOR CHANGING ACTIVATED CARBON ANDSYNGAS INTO DIESEL FUEL. All of the above applications are incorporatedherein by reference as if fully set forth herein.

FIELD OF THE INVENTION

The present invention relates to fluid flow beds used in the process ofconverting carbon based matter into natural gas and activated carbon andmore particularly related to the rate of fluid flow.

BACKGROUND OF THE INVENTION

Coal has long been used as a source of fuel. As the search foralternative fuels increases, several inventors have been looking towardfurther developing technology related to the use of coal. Theseinventors have come to recognize that the natural gas found in coal isnot limited to coal, but rather is found in various forms of man-madeand naturally occurring substances including, but not limited tomunicipal solid waste, sewage, wood waste, biomass, paper, plastics,hazardous waste, tar, pitch, activated sludge, rubber tires andoil-based residue.

The question has generally not been where one should look for naturalgas, but rather how to liberate the natural gas. This has led to severaldifferent confined gasification liquefaction techniques. These systemsin general terms include the down draft gasification, updraftgasification, and fluidized bed gasification.

The down draft gasification, also called a “co-current configurationsystem”, relies on gravity to move the feedstock, which perhaps is coal.The ignition system flows with the feedstock with resultant ash or slagfalling out the bottom. The ash or slag is hazardous waste and istreated as such. This system of partial combustion yields a low BTU gasthat must undergo extensive cleaning.

The updraft gasification, also called a “countercurrent system”, uses ablower to direct the feedstock up through the system. The combustionsource is generally directed in an opposite direction to the feedstockor perpendicular to it. The ash and slag falls out the bottom where itis collected as hazardous waste. This is a partial combustion systemthat results in low BTU gas and tars that must be cleaned prior to use.

The conventional fluidized bed uses sand, char or some combinationthereof. The fluid, usually air or steam, is directed through the sand,to the feedstock thereabove. The environment is usually oxygen starvedresulting in partial combustion. The temperatures are relatively lowresulting in low BTU gas that must be extensively cleaned prior to use.The ash is corrosive, invoking the use of limestone to minimize thecorrosive effect. Some examples of the fluidized bed technology follow:

Giglio (U.S. Patent Application 2006/0130401) discloses a method ofco-producing activated carbon in a circulating fluidized bedgasification process. The carbonacious material is treated in afluidized bed to form syngas and char. (¶14) In a subsequent step, thechar is turned to activated carbon with steam and carbon dioxide. Giglioteaches using the activated carbon to clean the syngas and separation ofthe gas and activated carbon. The cleaned syngas and solids areseparated in a dust. Giglio uses a separator to separate the activatedcarbon and natural gas from the feedstock. That is, the gaseous flowsthrough the fluidized bed are not used to separate components ofcarbonacious material on the basis of density.

Jha et al. (U.S. Pat. No. 5,187,141) discloses a process for themanufacture of activated carbon from coal by mild gasification andhydrogenation. The coal is first heated to a temperature betweenevaporation of water and below removal of volitilization. The dry coalis the heated in a mostly non-oxygenous atmosphere to volatilize andremove the contained volatile matter and produce char. In a second step,the char is subjected to a hydrogenation process to activate the carbon.The gaseous flows through the fluidized bed are not used to separatecomponents of carbonacious material on the basis of density.

Ueno et al. (United States Patent Application 2003/0027088) discloses amethod for treating combustible wastes. Combustible wastes includespaper, plastics, coal, tar, pitch, activated sludge, and oil-basedresidue. ¶8. The combustible wastes are carbonized at a temperature ofaround 400-600 degrees C. The carbonized material is then subjected to atemperature around 1000-1300 degrees C. in an inert atmosphere. Thisdrives off the volatiles and may activate the carbon. The carbonizedproduct is blown into exhaust gas, e.g., volatiles, to purify theexhaust gas. (Exhaust gas is preferred to be from refuse incineration,electric power plants, steel-making electric furnace, scrap meltingfurnace, and sintering machine.). The volatiles are used as a heatsource for the carbonization step, although they are acknowledged tohave harmful substances contained therein. ¶40.

The rate of fluid flow has generally not been discussed nor has thebenefits of the fluid flow rate been considered. What is needed is aflow rate of gas in fluidized bed during conversion of carbon basedmaterial to natural gas and activated carbon that yields beneficialresults that extend beyond the speed of combustion or conversion.Desirably, the flow rate separates material desired to be suspendedabove the fluidized bed from the material not desired to be above thebed.

SUMMARY OF THE INVENTION

The present method of processing carbonacious material into natural gasand activated carbon may include the steps of: placing feedstock onto afluidized bed; directing non-oxygenated gas through the fluidized bed;adjusting a velocity of the gas such that the gas is slow enough toleave the feedstock on the fluidized bed and fast enough to removeactivated carbon and volatiles.

In a preferred method, the process may include the steps of placingfeedstock onto a fluidized bed; directing superheated non-oxygenated gasthrough the fluidized bed; adjusting a velocity of the superheated gassuch that the gas is slow enough to leave the feedstock on the fluidizedbed and fast enough to remove activated carbon and volatiles; allowingcleaning of the volatiles using the activated carbon to form cleannatural gas and activated carbon; separating the natural gas and theactivated carbon; recycling a portion of the natural gas back to thefluidized bed; collecting a non-recycled portion of the natural gas; andcollecting the activated carbon.

Advantageously, the plenum leading away from the fluidized bed may be inan elevated position from the fluidized bed, permitting immediateco-mingling of the volatiles with the activated carbon yielding cleannatural gas and activated carbon.

As yet another advantage, the velocity keeps the fluidized bed with afresh supply of carbonacious material and self purges the processedmaterials from the fluidized bed.

As still yet another advantage, the process is completely devoid ofwater and oxygen, which leads to partial combustion, e.g. charring, orcomplete combustion, e.g. ash, and thus allowing the carbonaciousmaterial to proceed directly to activated carbon.

As still yet another advantage, the velocity operates as a gravityseparator relying on the change in density between the feedstock andmixture of activated carbon and volatiles.

These and other advantages will become clear from reading the belowdescription with reference to the appended drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart showing the present inventive method;

FIG. 2 is a block diagram showing the present inventive apparatus;

FIG. 3 is a flow chart showing the first process of the presentinventive method;

FIG. 4 is a diagram showing the first processor of the presentinvention;

FIG. 5 is a plan view of the fluidized bed of the first processor;

FIG. 6 is a schematic drawing of the airlock of the first processor;

FIG. 7 is a side view in partial phantom showing the blower assembly andseal assembly of the present invention;

FIG. 8 is a top or bottom view of the housing assembly of the blower ofthe present invention;

FIG. 9 is a bottom view of the seal assembly of the blower of thepresent invention;

FIG. 10 is a top view of the seal assembly of the blower of the presentinvention;

FIG. 11 is a right side portion of a partial cross-sectional view of thehousing and blower assemblies of the present invention taken along thelines 11 a-11 a and 11 b-11 b of FIG. 7.

FIG. 12 is a flow chart showing the second process of the presentinvention; and

FIG. 13 is a schematic drawing showing the various components of thesecond processor of the present invention.

The figures are presented as being the best mode of the presentinvention and are not to be deemed limiting in any regard.

DETAILED DESCRIPTION Definitions

The following terms, defined immediately below, have such meaningsthroughout the description and claims:

Activated carbon—a porous crystalline structure made primarily ofhydrogen deficient carbon. The carbon-to-carbon bonding within theactivated carbon may be varied, including single, double, triple andquadruple bonds structured in chains and rings and may include monomersand polymers randomly found in and throughout the activated carbon.Activated carbon is not achieved through an intermediate step involvingchar or ash or arrived at through combustion.

Activated char—not truly activated carbon, but rather an amorphouscarbon compound. Activated char may have an intermediary step ofcharring and involves partial combustion.

Amorphous carbon—a carbon compound with no particular structuralarrangement. Amorphous carbon may be hydrogenated or may be at ahydrogen deficit.

Char—Char is an amorphous carbon structure substantially hydrogendeficient. Char is often found as a by-product of incomplete combustionof organic compounds including fossil fuels and biomass due to a partialdeprivation of oxygen.

Crystalline carbon—a carbon compound with a definite structure.Crystalline carbon may be fully hydrogenated or substantially devoid ofhydrogen. Crystalline carbon and amorphous carbon as used herein areopposite terms.

Diesel—a fuel that may be represented by the chemical formula C12H23, onaverage, but is a mixture of hydrocarbons generally between C10H20 toC15H28.

Feedstock—any carbon based material, preferably, but not limited to coaland activated carbon. The feedstock should be dried and may have adiameter range between 1/16 and ⅝ inches and a preferred diameter rangeof between ⅛ and ¼ inch when used in the preferred mode.

Gas—one of the three states of matter and does not necessarily denotethe combustible matter. This invention is intended to be used in theproduction of combustible gas and where combustible gas is intended termthe term combustible, natural, diesel or other such distinguishing termwill be used.

Hydrogen deficient carbon—carbon compounds that lack sufficient hydrogento convert to diesel without hydrogenation.

Natural gas—Combustable material driven off of feedstock or manufacturedfrom carbon chains shorter, e.g. methane and ethane, than used in dieselfuel. Natural gas is used within the ordinary and common use of theterm.

Volatiles—gaseous material driven off of feedstock, which is generallycombustible. While possible that trace amounts of non-combustablematerial may be included in the volatiles, the levels may be trace orless. (None were found upon testing.) The components in testablequantities of first volatiles were entirely clean natural gas. The firstvolatiles are generally are 90+% methane with the balance being slightlylonger hydrocarbons. The second volatiles are presently not determined,but are understood to contain natural gas and hydrocarbons longer thannatural gas and shorter than diesel.

Detailed Description—Overview

The present invention is most readily understood in components, but maybe joined, integral or otherwise, into a comprehensive whole apparatus10. Fully described below are components including first processor 130,blower 210 and second processor 410 together with their respectivemanners of operation. In combination, these components 130, 210, and 410process feedstock 12 into diesel fuel 14 and natural gas 16.Intermediary by-product, including natural gas 16 and activated carbon18 may optionally be collected in user determined amounts. Under thissection, description—overview, is a look at the overall process and issupported by the first processor, blower and second processordescriptions below.

Numerals as used throughout are in part determined by the component inwhich the numeral is used. The part numbers are two digit when thenumeral is selected for description of the entire apparatus 10, partnumbers are three digit with a leading 1 when referring to firstprocessor 130, part numbers are three digit with a leading 2 whenreferring to the blower 210, and part numbers are three digit with aleading 4 when referring to second processor 410. Components such asactivated carbon, natural gas and others have multiple numbers with theleading digit indicating the section in which the component is beingdiscussed and the two digit corresponding to the other arts within theappropriate section.

The present inventive method of manufacturing diesel, may include thesteps of providing a feedstock 12, step 30 of FIG. 1; processing thefeedstock 12 to produce hydrogen deficient carbon material 20 and firstvolatiles 24, step 32; hydrogenating the hydrogen deficient carbonmaterial 20, step 34; and processing the hydrogenated hydrogen deficientcarbon material 20 into second volatiles 26 and diesel 14, step 36.

Stated in differently, in breadth and terms, the present method ofmanufacturing diesel, preferably includes the steps of: providing afeedstock 12 having a hydrogen deficient carbon material 20; andprocessing the hydrogen deficient carbon material 20 into a mixture ofvolatiles 22 and diesel 14. Included may be intermediary steps of:processing the feedstock 12 into a mixture of first volatiles 24 andhydrogen deficient carbon material 20; and processing the hydrogendeficient carbon material 20 into a mixture of second volatiles 26 anddiesel 14. The mixture of first volatiles 24 and hydrogen deficientcarbon material 20 may be a mixture of natural gas 16 and activatedcarbon 18, whereas the mixture of second volatiles 26 and diesel 14 mayinclude natural gas 16, hydrocarbons longer than natural gas 16 andshorter than diesel 14 and diesel 14.

The feedstock 12 may be selected from the group of coal, activatedcarbon, char, biomass and other carbon based matter. The hydrogendeficient carbon material 20 typically is activated carbon 18, but maybe carbon in any crystalline, amorphous or combined configuration,including, but not limited to various chars. The first volatiles 24preferably is natural gas 16. The second volatiles 26, while includingnatural gas 16, includes hydrocarbons longer than natural gas 16.

The present apparatus 10 for manufacturing diesel 14 may include afeedstock 12; a first processor 130, the processor 130 being adapted toconvert the feedstock 12 into a mixture of hydrogen deficient carbonmaterial 20 and volatiles 22. A blower 210 preferably is in fluidcommunication with the feedstock 12 and adjusted to separate thefeedstock 12 from hydrogen deficient carbon material 20 and volatiles22. The blower 210 desirably is positioned partially within the firstprocessor 130 and partially outside the first processor 130. Optionally,a second processor 410 may be operably joined to the first processor 210and adapted to convert hydrogen deficient carbon material 20 into amixture of diesel 14 and volatiles 22.

Stated differently, in breadth and terms, the apparatus 10 formanufacturing diesel 14 may include a feedstock 12 having hydrogendeficient carbon material 20 and a processor 410 adapted to convert thehydrogen deficient carbon material 20 into a mixture of diesel 14 andvolatiles 22.

Detailed Description—First Process/Processor

Reference numerals 110-126 are reserved for process steps and are foundon the flow chart designated as FIG. 3. Numerals 130 through 300 arereserved for apparatus components and are found on FIG. 4 through FIG.6.

The present method of processing feedstock 134 into first volatiles 154and hydrogen deficient carbon material 157 may have a first step 110 ofselecting a feedstock 134 as shown in FIG. 3. Suitable material fromwhich to generate feedstock 134 includes, but is not limited to, coal,municipal solid waste, sewage, wood waste, biomass, paper, plastics,hazardous waste, tar, pitch, activated sludge, rubber tires andoil-based residue. Coal is the preferred feedstock. The grade of coal isnot significant, since this is not a process involving partial orcomplete combustion. However, wet material, including coal, should bedried.

The feedstock 134 is then placed onto a fluidized bed 144, signified onFIG. 3 as step 112. This step preferably is done in a controlled mannerto preclude oxygen and/or water from entering with the feedstock 134.For instance, the feedstock 134 may enter through an airlock system 135.

The airlock system 135 may include a feed hopper 136, a screw auger 138,a rotary airlock 140, and a slide gate 142 with a sleeve 142 a andaperture 142 b. Feedstock 134 from the feed hopper 136 is directed bythe screw auger 138 to the rotary airlock 140. Rotating the rotaryairlock 140 drops feed stock 134 into the aperture 142 b of the slidegate 142. Oscillation of the slide gate 142 through the sleeve 142 adirects the feedstock 134 over the chute 184, whereupon the feedstock134 falls onto the fluidized bed 144. The feedstock 134 encounters aslightly elevated atmospheric pressure as it reaches the chute 184. Thispressurized atmospheric assures that any airflow through the air locksystem 135 is in an outward direction, not inward. Other airlock systemsare known to those of ordinary skill in the art and may be used in lieuof the disclosed airlock system 135.

The feedstock 134 is suspended in the superheated natural gas 149 of thefluidized bed 144. The feedstock 134 suspended on the fluidized bed 144is done in such manner that the feedstock 134 is supported by matterthat is in a gaseous state, e.g., the superheated natural gas 149.Feedstock 134 is floated in a gaseous stream. Superheated gas 149directed at the feedstock 134 forms the gaseous stream and is thepreferred matter that is in the gaseous state.

Superheated natural gas 149 is directed, see 114 on FIG. 3, through thefluidized bed 144, which converts the feedstock 134 into first volatiles154 and hydrogen deficient carbon 157. The hydrogen deficient carbon 157preferably is activated carbon 156 and what is stated as to activatedcarbon 156 applies to hydrogen deficient carbon 157. The temperatureneeds to be selected in consideration of the feedstock size, since thevolatiles 154 should all be released sufficiently fast to activate thecarbon. The feedstock 134 should be between 1/16 and ⅝ inches indiameter and preferably the size is between ⅛ and ¼ inches in diameter.This may be referred to as flash heating. The superheated natural gas149 is clean, and may be natural gas 149 obtained from this disclosedprocess, herein referred to as recycled. The superheated natural gas 149may be heated to a temperature between 1000 degrees F. and 1500 degreesF. and preferably is between 1000 degrees and 1200 degrees F. Thesetemperatures are found desirable in that they flash heat the feedstock134, driving off the volatiles rapidly e.g., seconds. The rapidvaporization, expansion, of the volatiles 154 activates the carbon.

The velocity, see element 116 of FIG. 3, of the superheated natural gas149 is adjusted such that the natural gas 149 is slow enough to leavethe feedstock 134 on the fluidized bed 144 and fast enough to remove amixture of activated carbon 156 and volatiles 154. The velocityseparates the feedstock 134, activated carbon 156 and volatiles 154based on density of the material, e.g. less dense material blows away(in a controlled manner). Feedstock 134 is more dense than activatedcarbon 156, which is more dense than volatiles 154. The velocity of thegas flow is thus set to move the less dense material, e.g. mixture ofvolatiles 154 and activated carbon 156 into a first plenum 152, allowingthe feedstock 134 to remain on the fluidized bed 144 for furtherprocessing. The velocity is slow enough so as to not remove thefeedstock 134. As the fluidized bed 144 continues to separate thevolatiles 154 from the feedstock 134, the feedstock 134 convertsdirectly to activated carbon 156 without an intermediary step ofcharring. The system, devoid of oxygen, does not have partial orcomplete combustion and thus does not form char or ash. The flow ratedepends on the size of the fluidized bed. A very small bed may have aflow rate of 10 cubic feet per minute, while a very large bed may have arate of 20,000 cubic feet per minute. Desirably, the velocity is between5500 and 6500 cubic feet per minute and most preferably is approximately6000 cubic feet per minute.

A displacer 182 may be positioned in the chute 184, perhaps verticallyocsillatable, may be used to adjust the size of the open area that isthe fluidized bed 144. This in turn increases the velocity of thenatural gas 149, assuming the overall flow rate, e.g., volume moved,remains unchanged. The displacer 182 beneficially allows for moreefficient carbon removal from the fluidized bed 144 and keeps thefluidized bed 144 cleaner. In practice, a displacer 182 performs withbetter results than altering the velocity through the use of increasedperformance from one or more blowers 168. The preferred blower 168 is asdescribed below in the section titled Description—Blower.

The activated carbon 156 and volatiles 154 are co-mingled from thefluidized bed 144 until the vortex separator 158 as will be discussed,see element 118 of FIG. 3. The activated carbon 156 in the mixture (orco-mingled collection) of volatiles 154 and activated carbon 156 isallowed to clean the volatiles 154 to form clean natural gas 149 andactivated carbon 156. Harmful compounds, such as mercury, chlorine andsulfur compounds, gather in, are collected by and are stored in theactivated carbon 156. The harmful compounds found in feedstock 134,commonly coal, are only known to liberate under conditions of combustionor application of a strong acid, neither one of which is found in thepresent invention. Accordingly, it is believed that harmful compounds donot liberate from the feedstock 134 and remain in the activated carbon156 never being part of the volatiles 154. Testing on the currentprocess has not shown any harmful compounds to be in the volatiles 154and that the volatiles 154 leaving the fluidized bed 144 are cleannatural gas 149. It should be noted that feedstocks 134 may havecombustable gases that would be volatiles 154, but be longer carbonchains than natural gas 149. Cleaning, however, is allowed to occur tothe extent any harmful substances do liberate. Cleaning the volatiles154 using the activated carbon 156 to form clean natural gas 149 andactivated carbon 156, may start at least as early as when the volatiles154 and activated carbon 156 are leaving the fluidized bed 144, with thecleaning process continuing through completion.

The activated carbon 156 is separated from the natural gas 149 in avortex separator 158, see element 120 of FIG. 3. The vortex separator158 is of the size and manner known to one skilled in the art. Thenatural gas 149 may be drawn by a blower 168 through a second plenum 162attached to the vortex separator 158, while the activated carbon 156settles out the bottom of the separator 158. The resultant natural gas149 is medium BTU natural gas, (1000 Btu/SCF). The activated carbon 156collected at the bottom of the vortex separator 158 may be cooled,screened, graded/processed and packaged for sale or may remain heatedand be used in the second processor 410 as will be described below. Theactivated carbon 156 ranges in size between a powder to ¼ inch diameter.The activated carbon 156 may be cooled in sealed cooling conveyors.

In a step of recycling 122 of FIG. 3, a portion, perhaps 10%, of thenatural gas 149 may be recycled back to the fluidized bed 144 and aportion, perhaps 5% or less, may go to be recycled to a burner 180 forcombustion that is used to superheat the gas for the fluidized bed 144.The non-recycled portion of the natural gas 149 may be collected asshown in step 124 of FIG. 3. Collecting 124 may include cooling,compressing and packaging the natural gas for sale. The activated carbon156 collected at the bottom of the vortex separator 158 may be packagedfor sale as identified in step 126 of FIG. 3.

Heretofore disclosed is a preferred method of processing feedstock 134into natural gas 149 and activated carbon 156. The process is not aburning or partial burning process, but rather a temperature and densitybased separation process. Hereinafter described is the preferredapparatus 130 in which to carry out the disclosed process. Referencewill be made to FIG. 4.

The processing apparatus 130 may have a feed hopper 136 joined to anairlock system 135. The airlock system 135 may have a screw auger 138, arotary air lock 140, and a slide gate 142 positioned in a sleeve 142 aand defining an aperture 142 b. The screw auger 138 draws feedstock 134from the feed hopper 136 and directs it into the rotary airlock 140.Turning the rotary airlock 140 drops feed stock 134 into the aperture142 b of the slide 142. Oscillating the slide 142 in the slide 142 a,allows the feedstock 134 to drop through the aperture 142 b into thechute 184 and to the fluidized bed 144.

Alternative airlock systems 135 known to those of ordinary skill in theart may be used. No air or water is to pass beyond the airlock system135. Either lead to combustion, which is not part of the presentprocess.

Beyond the airlock 135, the feedstock 134 reaches the fluidized bed 144.Typically, a fluidized bed relies on sand or char as the bed throughwhich the gas passes through. The present invention uses a metal grate146 with small apertures 148 therethrough; the apertures 148 beingsmaller than the feedstock particles 134. The natural gas 149,alternative gases not involving oxygen may also be used, directedthrough the fluidized bed 144 is superheated to a temperature describedabove. The natural gas 149 may be directed through one or more bedconduits 151, the number of which is selected to keep the natural gas149 moving at an even velocity substantially devoid of dead spots. Thevelocity, discussed supra, suspends the feedstock 134 and blows thevolatiles 154 and activated carbon 156 into a first plenum 152. Thefeedstock 134 is positioned on the fluidized bed 144, while superheatednatural gas 149 passes through the fluidized bed 144.

The natural gas 149 passing through the fluidized bed 144 has avelocity. The velocity is adjusted to a point such that the natural gas149 is slow enough to leave the feedstock 134 on the fluidized bed 144and fast enough to remove volatiles 154 and activated carbon 156. Assuch, the natural gas 149 flow is a separator of feedstock 134 from amixture of activated carbon 156 and volatiles 154, such separationoccurring on the basis of density.

The volatiles 154 and activated carbon 156 are allowed to co-mingle inthe first plenum 152 to clean the volatiles 154, if any harmfulcompounds have been liberated, into clean natural gas 149. (Upontesting, no harmful compounds were found to have been liberated at anypoint during the process and in the apparatus described herein, thus thevolatiles 154 were clean natural gas 149.) The plenum 152 is in fluidcommunication with the fluidized bed 144, being a receptor of a mixtureof volatiles 154 and activated carbon 156 mixture therefrom. The firstplenum 152, in fluid communication with the fluidized bed 144, may bepositioned at a point elevated above the fluidized bed 144 and be sizedand adapted to receive the volatiles 154 and activated carbon 156.Additional volatiles 154 are allowed to separate from the activatedcarbon 156 in the first plenum 152 which is maintained at or about thetemperature of the fluidized bed 144.

The first plenum 152 empties into a vortex separator 158, which is avolatile/activated carbon separator 138. Preferably, the vortexseparator 158 is heated to maintain the temperature of the natural gas149. The vortex separator 138 separates the volatiles 154 (natural gas149) from the activated carbon 156 based upon gravity. (Note: Thevolatiles 154, after co-mingling with activated carbon 156 in the firstplenum 152, is clean natural gas 149 and, after the first plenum 152,volatiles 154 and natural gas 149 are interchangeable terms.) Inessence, the activated carbon 156 falls out an aperture 160 in thebottom of the vortex separator 158. The volatiles 154 are drawn into asecond plenum 162 designed for cooling, compressing, recycling,packaging natural gas as will now be described.

The second plenum 162 may include one or more blowers 168 positioned tomaintain or adjust the velocity of the natural gas 149. The secondplenum 162 joins to third and fourth plenums 164,166 respectively. Aportion, perhaps 10%, of the natural gas 149 may be directed through thethird plenum 164 to a heat exchanger 170 and back to the fluidized bed144. (Insulation 147 may surround the fluidized bed 144 or the entireapparatus 130.) The heat exchanger 170 superheats the natural gas 149prior to entry into the fluidized bed 144. The remaining natural gas149, perhaps 90%, is directed into the fourth plenum 166 where it mayinteract with a heat exchanger 172 for cooling, a low pressurecompressor 174 and bulk storage 176, ready for sale. A gas line 178 maylead from the bulk storage 176 to a burner 180 associated with the heatexchanger 170. The burner 180 combusts the natural gas 149 and providesheat to the heat exchanger 170. Post combustion gases, from the burner180, may be directed up the stack 150.

The first processor and first process have been disclosed in a mannerunderstandable to those of ordinary skill in the art with reference tofigures, which form a part of the disclosure herein, describing the bestmode of making and using the present invention as known to the inventorhereof. Those of ordinary skill in the art will discern alterationswhich may be made without departing from the spirit and scope of thepresent invention as set forth in the claims below.

Detailed Description—Blower

The present high temperature blower with environmental seal 210 mayinclude a blower assembly 220, shaft 242, motor 246, housing assembly260 and seal assembly 280. These components cooperate to form a blower210 suitable for operation in high temperature environs where the blower210 and motor 242 need to operate in separate atmospheres. Thesecomponents will be discussed in serial fashion.

The blower assembly 220 may be any blower assembly known to thoseskilled in the art. Shown in FIG. 7 is a top plate 222 (also shown inFIG. 8), a bottom plate 224, a wrapper 226, outlet plate 228 and outlet230, which cooperate to define a housing 232. The top plate 222 shown inFIG. 8 may be the same shape as the bottom plate 224. The housing 232defines a chamber 234 in which the fan blades 236 move the gas in acyclonic motion and direct the gas out through the outlet plate 228.Thus, gas may enter through an inlet 238, be accelerated and moved outthrough the outlet 230 defined in the outlet plate 228. Inside thehousing 232, may be fan blades 236 and a spider 240.

The shaft 242 joins to the spider 240, which in turn is joined to thefan blades 236. The shaft 242 passes through a shaft opening 244 in thebottom plate 224 of the blower assembly 220, through the housingassembly 260 and the seal assembly 280, connecting to the motor 246. Themotor 246 turns the shaft 242 thereby effecting movement of the fanblades 236 to direct gas in through the inlet 238 and out through theoutlet 230. Various structural supports 248 may provide support betweenthe blower assembly 220 and the motor 246. A bearing 250 may stabilizethe shaft 242 relative to the motor 246. The housing assembly 260 isshown joined to the seal assembly 280, which in turn is joined to thebottom plate 224. A projection 252 on the seal assembly 280 may projectinto the blower assembly 220.

FIGS. 9-11 show the housing assembly 260 and seal assembly 280. As canbe seen from FIGS. 9 and 10 the housing assembly 260 and seal assembly280 are generally cylindrical, but may include protrusions that allowfor bolts or other fasteners to pass therethrough.

Turning to FIG. 11, the housing assembly 260 may include an outerhousing 262, which serves to encase a bearing 264. The bearing 264 mayfurther include a bearing sleeve 266 that engages the shaft 242 on aside opposite a ball bearing 268. A grease port 270 preferably providesfluid communication with the ball bearing 268. The housing assembly 260joins to the seal assembly 280 perhaps with fasteners 272.

It should be noted that the housing assembly 260 and seal assembly 280,being generally cylindrical are generally symmetrical, when looked at incross section. To increase clarity, only one half of the cross section,e.g. one-quarter of the whole, is shown together with a portion of theshaft 242.

The seal assembly 280 may include a first housing portion 282 and asecond housing portion 284 cooperatively define a coolant channel 286.O-rings 288,290, having differing diameters, provide a seal between thefirst and second housing portions 282,284. Ports, not shown, arepreferred to be on opposite sides of the seal assembly 280. In thismanner, coolant 292 may be directed into the coolant channel 286, flowaround each side of the seal assembly 280 and out an exit port.

Positioned between the first and second housings 282,284 and the shaft242 is a sleeve 294. The sleeve 294, which adds rotational support,rotates with the shaft 242 and has a collar 296 positioned at one endand inner gland 295 at the other end. The collar 296 is secured via aspacer 297 which may be fastened with at least one bolt 298 to the firsthousing 282. The inner gland 295 allows any heated gas that may passthrough the shaft opening 244 to be received in a chamber 299. Thechamber 299 is positioned adjacent the first and second housing portions282,284 on a side opposite the coolant channel 286, thus defining a heatexchanger 300 therebetween. The gas within the chamber 299 remainsrelatively stagnant as there is no exit port and accordingly remainscooled by the coolant 292. Unintended exit ports are sealed with o-ringsand oil in an outer gland, yet to be described.

A rubber o-ring 302, positioned in the sleeve 294, prevents gas thatpassed through the shaft opening 244 from further movement along theshaft 242. A gasket 304, preferably formed of graphfoil, prevents gasthat passed through the shaft opening 244 from escape around the outsideof the first and second housing portions 282,284. Thus, the o-ring 302and gasket 304 preclude gas that passed through the shaft opening 244from movement except into the chamber 299. The seals blocking escape ofthe gas from the chamber 299 are incorporated into the machined housing306 for maintaining the sleeve 294.

The machined housing 306 maintains the sleeve 294 in alignment with theshaft 242 and seal assembly 280. Positioned adjacent the collar 296 is alip seal 308. The lip seal 308 can be positioned in a void 310containing oil 312 as a lubricant and as a seal to keep gas from theblower assembly 220 from escaping the seal assembly 280. The lip seal308 rotatably secures one end of the sleeve 294. The oil 312 acts as alubricant between parts that remain stationary relative to the sealassembly 280, such as the lip seal 308, and the components that rotatewith the sleeve 294 as hereinafter described.

Moving from right to left, FIG. 11 shows a pin 314, which secures amating ring 316 to the seal assembly 280. The mating ring 316 ispreferred to be formed of silicon carbide for its strength, frictionco-efficient and heat bearing properties. An o-ring 318 precludes gasfrom movement around the mating ring 316 further sealing the chamber299. The lip seal 308, the pin 314, and the mating ring 316 do notrotate with the sleeve 294 and accordingly are lubricated with oil 312.

Spring 320 is shown biased against and between a retainer 322 and a disc324. The disc 324 transfers the force of the spring 320 to a primaryring 326. The spring 320, retainer 322, disc 324, and primary ring 326rotate with the sleeve 294 and apply pressure on the sleeve 294 in adirection away from the lip seal 308, thereby providing secure controlof the sleeve 294 as it rotates with the shaft 242. The point of contactbetween the primary ring 326 and mating ring 316 is lubricated with oil312, since the two rings 326, 316 move with respect to each other. Theretainer 322 may fasten the primary ring 326 to the sleeve 294. Ano-ring 328 may optionally be provided to further seal gas from theblower assembly 220 from escaping the chamber 299.

As one can discern from reading the above with reference to the figures,heated gas from the blower assembly 220 is effectively sealed in thechamber 299 through various o-rings, gasket 304 and oil 312. Thus, thegas remains stagnant and does not transfer heat from the blower assembly220 to the o-rings. The shaft 242, however, may be thermally conductiveand can transfer heat from the blower assembly 220 and a cooling effectfrom the portion of the shaft 242 adjacent the motor 246 to the sealassembly 280. Since the o-rings, and in particular o-ring 102 is closerto the blower assembly 220 than the motor 246 it could become heatedespecially in extreme temperature changes. However, the heat exchanger300, transfers heat from the shaft 242 and sleeve 294 to the coolant292, maintaining the o-rings, and in particular o-ring 302 at safeoperating temperatures.

In use, the blower 210 includes the blower assembly 220 and sealassembly 280 joined to the blower assembly 220. The seal assembly 280may further include at least one seal, such as O-rings 302, 328, gasket304 or oil 312 and coolant 292, the coolant 292 being in thermalcommunication with at least a portion of the seal. The blower 210 can bepositioned in two separate environments. The first environment may havea first temperature and containing a gas of a first type, but not thesecond type; and the second environment, having a second temperature andcontaining a gas of a second type, but not the first type.

For example, the preferred use of the blower 210 has the blower assembly220 positioned in the first processor 130 where the temperature is atleast 1000 degrees F. and most likely approximately 1200-1500 degrees F.and have a gas being combustible gas. The seal assembly 220 and motor246 may be positioned in an environment where the temperature is no morethan 100 degrees F. and the environmental gas is oxygenated. The shaft242, rotatably joining the blower assembly 220 to the motor 246, maypass through both the first and second environments without the twoenvironments intermixing. The seals preclude the gases from theenvironments from intermixing and the coolant 292 keeps the twoenvironments at the preferred operating temperatures. (Note, mixingoxygen with the superheated combustible gas could cause undesiredcombustion and the motor 246 operates better at a temperature preferablyat or below 100 degrees F.)

The coolant 292, which desirably is water, could be any thermallyconductive flowable material such as anti-freeze and temperatureadjusted gases. The coolant 292 may be in thermal communication with theseals, perhaps in a water jacket, such as coolant channel 286.Alternatively, the seal assembly may have any other heat exchanger 300in thermal communication with the seals.

In operation, the motor 246 rotates the shaft 242, which rotates the fanblades 236. The seals, such as such as O-rings 302, 328, gasket 304 oroil 312, precludes commingling of gas from around the blower assembly220 with that around the motor 246. Flowing coolant 292 in thermalcommunication with the seals maintains a temperature at which the sealsdo not degrade and remain operable. That is, placing a heat exchanger300 in thermal communication with the seals keeps the seals at anoperable temperature.

The blower has been described with reference to the drawings in a mannerto fully disclose the best mode of making and using the presentinvention. Substantive and material changes may be made withoutdeparting from the spirit and scope of the present invention. Forinstance, the blower assembly 220 may be in a super cooled environment,instead of super heated, from which the motor may need to remainremoved.

Detailed Description—Second Process/Processor

The second processor (a fuel processing device) 410 may includegenerating mechanism 420 and converting mechanism 430. The convertingmechanism 430 may further include reducing mechanism 440, hydrogenatingmechanism 450, a microwave 460, a catalyst 470 and a distillationapparatus 480. A flow chart, FIG. 12, is provided to show the varioussteps in the second process and such process is generally discussedthroughout.

A suitable microwave 460, catalyst 470 and distillation apparatus 480are described in the reference Thermal catalytic depolymerization (Rev.15) Jan. 20, 2007, Bionic Microfuel Technologies, A.G. Such descriptionis incorporated into this disclosure by reference. Each of thesecomponents will be described in serial fashion.

The generating mechanism 420, shown schematically in FIG. 13, producesfeedstock 222, which may include activated carbon 424, char 426, coal428 and/or other hydrogen deficient matter. Suitable generatingmechanisms 420 include purchase of feedstock 422 on the open market.Production of feedstock 422 in the first processor 130 as describedabove. Production of feedstock 422 through manners described in theprior art, which is incorporated herein by reference, or manners knownto those skilled in the art.

The reducing mechanism 440 of the converting mechanism 430 changes thefeedstock 422 to a desired percentage of amorphous carbon 442. Theactivated carbon 424 is anticipated to be consistent throughout a batch431 and may range from 100% amorphous to 100% crystalline and everythingin between. Together the amorphous carbon 442 and crystalline carbon 444preferably make up the totality of feedstock 422, e.g. 100%. Theactivated carbon 424 may be converted to amorphous carbon 442 allowingmore complete hydrogenation. Accordingly, testing apparatus 446 may beprovided for determining the percent concentration of amorphous carbon442 and percent crystalline carbon 444 in a batch 431 of feedstock 422.Such testing apparatus may be X-ray crystallography, powder diffraction(SDPD) as disclosed in information by such companies as Inel, Rigaku MSCand Bede Scientific Instruments Ltd or performed in any other mannerknown to those skilled in the art.

The crystalline (activated) carbon 444 may need to be decrystallized ordepolymerized, which may be done in the microwave 460 described below.Accordingly, the knowledge of percent amorphous carbon 442 versuscrystalline carbon 444 may be used to determine the process, dwell time,and energy applied to the crystalline carbon 444 to yield a desiredpercentage of amorphous carbon 442 with the lowest expenditure ofresources. The desired level of amorphous carbon 442 may be 100% or alesser figure.

The reducing mechanism 440 may include the microwave 460 described belowor may be heat from any source, chemicaldepolymerization/decrystallization and/or other manners known to thoseof ordinary skill in the art of producing amorphous carbon 429,including oxygen starved superheating.

The feedstock 422 has at least a useable portion that is devoid orsubstantially devoid of hydrogen atoms as is needed in the generation ofdiesel 490. Substantially devoid, refers to a deficiency of adequateproportion to preclude full formation of the hydrocarbons in diesel 490.Accordingly, the hydrogenating mechanism 450 joins hydrogen atoms tocarbon atoms, while the carbon is in either a feedstock form 422, e.g.,activated carbon 424, char 426, short hydrocarbon chains (natural gas)and/or coal 428 and have either an amorphous carbon 442 or crystallinecarbon 444 structure, preferred is amorphous carbon 442. Such a chemicalreaction is endothermic. The hydrogenating mechanism 450 may include aheat source 452 and hydrogen gas or any other suitable hydrogen source454. The heat source 452 may take the form of the feedstock 422 beingpre-heated to a temperature between 340° F. and 650° F. at any pointbetween and including the generating mechanism 420 and microwave 460 orbeing heated by the microwave 460. While the feedstock 422 is heated toa temperature at or above 340° F., the feedstock 422 is subjected to thehydrogen gas 454. Carbon, hydrogen and combinations thereof are volatileat high temperatures, allowing the hydrogenation. Accordingly, thefeedstock 422 may be maintained at a temperature at or below the flashpoint of carbon, preferably at or below 300 degrees C. and/or maintainedin a non-oxygenated atmosphere.

For instance, where the generating mechanism 420 is the first processor130 as described above, the activated carbon 424 in the vortex separatoris at an elevated temperature and as such may be subjected to hydrogen454 in a non-oxygenated atmosphere. As described below, the feedstock422 in the microwave 460 is held at a sufficiently high temperature,300° C. or perhaps higher, and may be subjected to hydrogen gas 454 atthat point. The preferred point of positioning the hydrogenationmechanism 450 is at the microwave 460, since the feedstock 422 isreduced to amorphous carbon 442, rendering higher yields ofhydrogenation an ultimately diesel fuel 490.

The microwave 460 operates in conjunction with a catalyst 470 in thepresence of feedstock 422 and preferably in the presence of hydrogen gas454. Accordingly, the microwave 460 and catalyst 470 is structure andadapted to polymerize hydrocarbons shorter than twelve hydrocarbons,reduce activated carbon 424 to amorphous carbon 442, hydrogenateactivated carbon 424, char 426 and/or coal 428 while in an amorphouscarbon 442 or crystalline carbon 444 structure, and break hydrogenatedcarbon chains at or around the twelve to fourteen carbon length. Thereducing mechanism 440, hydrogenating mechanism 450 and microwave 460can be separate units as indicated in FIG. 13 or be combined into asingle unit within the microwave 460, with the combination beingpreferred. Through testing, the preferred operational perimeters are:frequency is 2.45 gigahertz, dwell time of one second to ten minutes,based on a preferred particle size of ¼ inch to ⅜ inch. The preferredcatalyst 470 is zeolite (alumina-silicate).

The polymerization process may include true polymerization processes inwhich carbon atoms double bonded to other carbon atoms, such as may befound in activated carbon 424, have the double bond broken creatingcites for attachment of another monomer. Polymerization may also includebreaking the crystalline structure of activated carbon 424, rings andthe like, temporarily forming elongated hydrocarbon chains of varyinglengths, e.g., amorphous carbon 442.

The zeolite catalyst 470 responds to the microwave at a frequency of2.45 gigahertz. At this point, the zeolite 470 polymerizes the feedstock422, forming single bond carbon chains with the otherwise vacant bondingcites. At or above the temperature 250° C. hydrogen atoms from thehydrogen gas 454 join to the vacant bonding cites forming hydrogenatedcarbon chains. At a second temperature of 350° C., the zeolite 470generally breaks the carbon chains at the 14 to 16 carbon length. Thecarbon length is believed to relate to the frequency of the microwaveenergy.

The microwave 460 applies energy to the feedstock 422, which may be coal428, at a temperature at or about 300° C. Essentially, the catalyst 470forms a temporary bond with the prepared feedstock 422. The catalyst470, with applied energy shakes/vibrates, forming hydrogenated andelongated carbon chains. Eventually, the carbon chains reach such alength that the vibration of the catalyst 470 breaks the carbon chain.Through testing, it has been determined that the vast majority of thecarbon chains were between 14 and 16 carbon atoms in length, which ishigh grade diesel fuel 490.

The microwave 460 does not simultaneously convert all feedstock 422 todiesel 490. Accordingly, a distillation process may be used to separatethe various residue from the diesel 490. The distillation apparatus 480may include a condenser 482, a thermometer 484 and containers 486. Thehigh temperature feedstock 422 is above the evaporation point coming outof the microwave 460. The condenser 482 cools the gaseous feedstock 422.At various temperatures, condensation will form, indicating a quantityof a particular compound. Condensation that forms at 340° F.-650° F.degrees is diesel 490 and is directed to the containers 486. Thedistillation apparatus 480 is structured and adapted to separatehydrocarbon chains generally between twelve and fourteen carbons inlength. Gases still yet to condense are generally short hydrocarbonchains to be recycled.

There are essentially two non-recycled by-products. The first is thedesired diesel fuel 490, which is collected, cooled, packaged anddelivered to a point of further distribution or use. The secondby-product is residue 488. The residue 488 may include unreactedactivated carbon 424 which maintains the mercuric sulfides and otherinorganic compounds, a portion of the catalyst 470 and other inorganiccompounds. The residue 488 is collected and disposed of according tolawful standards. Condensation that forms at alternate temperatures isgenerally shorter length hydrocarbon chains to be recycled back into anelectrical generator 492, which may power the microwave 470.

Example 1

A sample was prepared according to the present disclosure. Inparticular, activated carbon was secured from a first processor 130. Thesample of activated carbon was measured and weighted. Catalyst was addedand the sample was transferred to a reactor flask. The flask was placedin a microwave reactor and processed at the desired temperature anddwell time. The resultant distilled diesel fuel had the characteristicsthat would meet or exceed ASTM D 975 standards. Meeting or exceedingASTM D975 would allow the diesel fuel to be sold to the public.

The second processor 410 has been fully described with reference to theappended drawings and the best mode of making and using the presentinvention known at the time of filing. One can see that variousmodifications can be made without departing from the spirit and scope ofthe present invention as is set forth in the claims below.

CONCLUSION

The apparatus 10 and method associated therewith has been fullydescribed above including the first processor 130, the blower 210 andthe second processor 410 together with their respective manners ofoperation. In combination, these components 130, 210, and 410 processfeedstock 12 into diesel fuel 14 and natural gas 16. Intermediaryby-product, including natural gas 16 and activated carbon 18 mayoptionally be collected in user determined amounts. The description ofthe apparatus 10 and overall process has been supported by thedescriptions of the first processor, the blower and the secondprocessor.

The apparatus 10 has been described with reference to the appendeddrawings and the best mode of making and using the present inventionknown at the time of filing. One can see that various modifications,some of which have been mentioned can be made without departing from thespirit and scope of the present invention as is set forth in the claimsbelow.

1. A method of processing carbonacious material into volatiles andactivated carbon, comprising the steps of: placing feedstock onto afluidized bed; directing superheated non-oxygenated gas through thefluidized bed; adjusting a velocity of the superheated gas such that thegas is slow enough to leave the feedstock on the fluidized bed and fastenough to remove activated carbon and volatiles; allowing cleaning ofthe volatiles using the activated carbon to form clean volatiles andactivated carbon; separating the volatiles and the activated carbon;recycling a portion of the volatiles back to the fluidized bed;collecting a non-recycled portion of the volatiles; and collecting theactivated carbon.
 2. The method of claim 1 wherein the feedstockcomprises at least one member selected from the group consisting of:coal, municipal solid waste, sewage, wood waste, biomass, paper,plastics, hazardous waste, tar, pitch, activated sludge, rubber tiresand oil-based residue.
 3. The method of claim 1 wherein the superheatedgas is heated to a temperature between 1000 degrees F. and 1500 degreesF.
 4. The method of claim 3 wherein the superheated gas is heated to atemperature between 1000 degrees F. and 1200 degrees F.
 5. The method ofclaim 1 wherein the superheated gas is natural gas.
 6. The method ofclaim 5 wherein the natural gas is clean natural gas.
 7. The method ofclaim 6 wherein the clean natural gas is recycled.
 8. The method ofclaim 1 wherein the natural gas is medium BTU natural gas.
 9. The methodof claim 1 further comprising the step of vaporizing the volatilessufficiently fast to activate the carbon.
 10. The method of claim 1further comprising the step of: floating the feedstock in thesuperheated gas.
 11. The method of claim 1 further comprising the stepof: co-mingling the activated carbon and volatiles.
 12. The method ofclaim 1 further comprising the step of: cooling the non-recycled portionof the volatiles.
 13. The method of claim 12 further comprising the stepof: compressing the cooled volatiles.
 14. The method of claim 1 whereinthe velocity is between 10 cubic feet per minute and 20,000 cubic feetper minute.
 15. The method of claim 14 wherein the velocity isapproximately 6000 cubic feet per minute.
 16. The method of claim 1further comprising the step of recycling a portion of the volatiles to aburner, the burner indirectly superheating the volatiles of thefluidized bed.
 17. The method of claim 1 wherein the step of directingsuperheated gas through the fluidized bed converts the feedstock intovolatiles and activated carbon.
 18. The method of claim 1 furthercomprising the step of: separating the feedstock from volatiles andactivated carbon as the feedstock converts to volatiles and activatedcarbon.
 19. The method of claim 1 further comprising the step of:separating the volatiles and activated carbon from the feedstock usingthe superheated gas to effectuate the separation.
 20. The method ofclaim 1 further comprising the step of: allowing cleaning of thevolatiles using the activated carbon to form clean natural gas andactivated carbon, such cleaning starting at least as early as when thevolatiles and activated carbon are leaving the fluidized bed andcontinuing through completion.
 21. A method of processing carbonaciousmaterial into gas and activated carbon, comprising the steps of: placingfeedstock onto a fluidized bed; directing non-oxygenated gas through thefluidized bed; adjusting a velocity of the gas such that the gas is slowenough to leave the feedstock on the fluidized bed and fast enough toremove activated carbon and volatiles.